Optical element, metal die, and cutting tool

ABSTRACT

An optical element has diffractive grooves. Each diffractive groove includes a first surface approximated by a predetermined optical function; a second surface extending in a direction to cross the first surface and being parallel to the optical axis; and a third surface to connect the first surface and the second surface. A width of the third surface in the direction perpendicular to the optical axis is 0.5% to 15% of the sum of a width of the first surface in the direction perpendicular to the optical axis and the width of the third surface in the direction perpendicular to the optical axis.

BACKGROUND OF THE INVENTION

[0001] This invention relates to an optical element having diffractivegrooves, a metal die for forming it, and a cutting tool for the die, andin particular, to an optical element with a reduced loss of lightquantity to make the effective light quantity near to 100%, and a metaldie and a cutting tool for obtaining an ideal diffractive opticalelement by taking into consideration factors such as a shape ofdiffractive grooves, surface roughness, conditions of working the metaldie, a tool for working the metal die, resin material.

[0002] A diffraction optical element is an optical element such thatsawtooth shaped steps are provided on an optical surface of an opticalelement, diffraction is generated by varying the phase of a light wavepassing there, to utilize the function to deflect the optical path. Fora bundle of rays refracted by a basic aspherical shape, by furtherdeflecting the optical path by the effect of diffraction, it can exhibitwith a single optical surface a diffraction effect equivalent to thatwith two optical surfaces. On top of it, an optical path is moredifficult to be deflected the longer the wavelength is in the case ofrefraction, but an optical path through diffraction is more deflectedthe longer the wavelength is; therefore, the wavelength dependency ofrefraction can be reduced by combining the both.

[0003] For an example of application of a diffractive lens, animage-sensing lens for a camera provided in a personal computer, apickup optical element for an optical disk etc. can be cited. The formercan make chromatic aberration smaller efficiently with a small number oflens pieces by using diffraction effect; therefore, it actualizes animage-sensing lens which is thin, of light weight, and convenient forbeing provided in a personal computer. Further, for an example of thelatter, it can be cited an objective lens which is used in correctingthe aberration owing to the wavelength fluctuation of a high-outputlaser diode as a light source which is generated at the time of writinginformation after it is read out from an optical disk such as a DVD or aCD.

[0004] Further, in order that different optical disks such as a DVD anda CD may commonly use a single optical element, an optical elementutilizing a diffraction effect is employed to correct satisfactorilyaberration for a plurality of light-source wavelengths and to securesatisfactory chromatic aberration characteristics against wavelengthfluctuation owing to temperature variation and a mode hop.

[0005] However, in the case of the former lens, if scattering isproduced on an optical surface or inside a lens, a flare appears in theformed image to reduce the contrast, which deteriorates the imagequality sharply. Especially in the case of a diffractive lens, becauseof the discontinuous optical surface, it is difficult in designing thelens to make diffraction efficiency 100% for whole incident light in theangle of view, and it has a characteristic such that a certain amount ofscattering is produced even if it is ideally produced.

[0006] Accordingly, in manufacturing a diffractive lens, in order toreduce scattering by the lens to a level practically of no problem, itis more important than a case of a usual lens to generate the shape ofits optical surface which is nearest to the designed shape as much aspossible. As for the level of scattering of no practical problem, alevel not higher than 5% of incident light quantity, or more desirably alevel not higher than 3% is required. This is equivalent to the surfacereflectivity of an optical surface made of the representative opticalglass such as BK7 in the case where it has not been coated with areflection reducing coating, and it is the criterion in asking for anecessary image quality and a merit of employing a diffractive opticalsurface that the loss of light quantity by scattering is at least notmore than that by reflection in the state of no reflection reducingcoating.

[0007] Further, in the case of the latter optical element in a pickupsystem for an optical disk, because the shortening of life and loweringof reliability are generally more remarkable, the higher power a laserdiode outputs, it is preferable to use a laser diode at a low output asmuch as possible; therefore it is necessary to reduce the loss of lightquantity such as scattering in the optical path as much as possible inorder to secure a sufficient light quantity in writing.

[0008] For a permissible range of the above-mentioned light quantityloss, it is usually obtained a value not larger than 10% of theremainder when an incident light quantity is subtracted by the surfacereflection component, or more desirably, a value not larger than 5% ofit. This value is empirically obtained by synthesizing such factors asthe alignment of the optical element, the light quantity dispersion oflaser diodes, the sensitivity dispersion of light receiving devices.

[0009] As described in the above, in an optical element utilizingdiffraction, as compared to a usual optical element having a continuousoptical surface, an influence of scattering etc. is easy to be producedremarkably; accordingly, it is important to obtain an ideal diffractionefficiency without loss of light quantity by scattering, and for thatpurpose, first of all, it should be mentioned that a diffractive opticalsurface must be produced in such a manner as to have an ideal shape.

[0010] However, in the manufacturing of a conventional diffractiveoptical element, it is not clear what degree of an error would bepractically of no problem for the above-mentioned ideal shape, and inthe case where a metal die for forming and transferring a diffractiveoptical surface is cut-worked, also with respect to the shape of thecutting part of a tool, only it is known that the edge should be madesharp, but it is not clear that to what degree the edge should besharpened, or what kind of a side effect is produced when it is madesharp.

[0011] Further, there has been no idea such that the apex angle of atool required should be made definite by taking into consideration theparallelism of the step section of diffractive grooves to the incidentbundle of rays. Further, also it has not been clear a threshold value ofsurface roughness to reduce scattering sufficiently at the portion of anoptical surface other than the step sections of diffractive grooves.Also for the material to make up the transfer optical surface of a metaldie, there has not been a concept that a high-machinability material isnecessary in order to maintain the sharp edge of a cutting tool byreducing the wear during working. Because of that, the sharpness of thecorner of a cutting part of a tool becomes dull only by cut-working asmall number of metal dies. As the result, generation of an ideal shapeof diffractive grooves is made impossible, and the following problemshave been frequently observed, which are that scattering of an incidentbundle of rays is brought about, taking more time for working theoptical surface of a metal die than necessary, that scattering becomeslarger by an insufficient precision of working, etc.

SUMMARY OF THE INVENTION

[0012] This invention was performed by considering main causes of theabove-mentioned points, and it is an object of the invention to providea metal die capable of actualizing the manufacturing of a diffractiveoptical element having a good efficiency, a tool for the die, and anoptical element manufactured by the die.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 is a cross-sectional view of an optical element accordingto this invention;

[0014]FIG. 2 is an enlarged cross-sectional view in the direction of theoptical axis showing a portion near one of the diffractive grooves of anoptical element;

[0015]FIG. 3 is a perspective view showing a double or triple spindlesuper-precision lathe;

[0016]FIG. 4 are drawings showing a tool for cutting a metal die; FIG.4(a) is a perspective view, FIG. 4(b) is the front view of the cuttingpart, and FIG. 4(c) is the side view of the cutting part;

[0017]FIG. 5 is a graph showing the lowering of diffraction efficiencyfor a single light-source wavelength in a sawtooth-shaped diffractiveoptical surface of a flat plate, when diffractive grooves are cut-workedby using a tool having the arc-shaped corner of the cutting part inworking the metal die;

[0018]FIG. 6 is a drawing showing the relation between wavelength usedtaken for the abscissa, and the diffraction efficiency of an opticalelement taken for the ordinate;

[0019] FIGS. 7(a) to 7(c) are drawings showing the relation betweensetting positions of a metal die and a tool at the time of cut-working;

[0020]FIG. 8 is a drawing showing the relation between a tool 70 and ametal die 50 during cutting by a lathe;

[0021]FIG. 9 is a drawing showing a cross-section of a metal die; and

[0022]FIG. 10 is a perspective view of a new tool according to thisinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0023] An optical element as set forth in (1) is an optical elementwhich comprises, at least in a part of an optical surface, diffractivegrooves (the first groove as counted from the optical axis is notincluded) provided with at least a first surface approximately expressedby a specified optical function and a second surface extending to thedirection crossing said first surface, and is capable of transmittinglight, wherein said first surface and said second surface of saiddiffractive grooves are connected by a third surface which is notapproximately expressed by said optical function, said second surface isparallel to the optical axis with an angular error not greater than 1°,and the width of said third surface in the direction perpendicular tothe optical axis is not smaller than 0.5% and not larger than 15% of thesum of the width of said first surface connected to it in the directionperpendicular to the optical axis and the width of said third surface inthe direction perpendicular to the optical axis; therefore, scatteringof an incident bundle of rays is suppressed to the utmost, andtransmitted light quantity can be raised.

[0024] This invention will be explained in more detail by referring tothe drawings. FIG. 1 is a cross-sectional view of an optical element,and FIG. 2 is an enlarged cross-sectional view in the direction of theoptical axis showing a portion near one of the diffractive grooves. InFIG. 2, the optical element 10 comprises an optical surface 10 a at theleft side in the drawing. On the optical surface 10 a, one of thediffractive grooves 14 is formed. The diffractive groove 14 is formed ofthe first surface 11 which is approximately expressed by a basicaspherical surface and a phase difference- or an optical pathdifference-function, the second surface 12 which is parallel to theoptical axis with an angular error not larger than 1°, and the thirdsurface 13 which connects these. The width Δ1 of the third surface inthe direction perpendicular to the optical axis is not smaller than 0.5%and not larger than 15% of the sum of the width Δ2 of said first surface11 connected to it in the direction perpendicular to the optical axisand the width Δ1 of the third surface 13 in the direction perpendicularto the optical axis. That is, the following expression should besatisfied:

(Δ1+Δ2)×0.5/100≦Δ1≦(Δ1+Δ2)×15/100.

[0025] Because the third surface 13 is not expressed approximately by abasic aspherical surface and a phase difference- or opticaldifference-function, it is a region not concerning the improvement ofthe optical performance of the optical element 10; hence, it should benarrow as much as possible. However, because the corner of the cuttingpart of a tool has a certain size, in manufacturing a metal die, asurface of the metal die corresponding to the third surface 13 isinevitably formed. Therefore, by making this surface small to theutmost, the third surface is controlled to be narrow as described in theabove, by which the transmitted light quantity through the opticalelement 10 is secured sufficiently.

[0026] As shown in FIG. 1 and FIG. 2, the shape of the diffractivegrooves has a shape which has steps and is patched and darned withaspherical surfaces, and because a bundle of rays from a light sourceproduces phase differences owing to these steps to generate diffraction,a function to deflect the path of the transmitted light in a specifieddirection is produced. If a bundle of rays transmitted through thisdiffractive optical surface has a light quantity equal to 100% of avalue which is obtained by subtracting the surface reflection componentowing to the refractive index difference from the incident bundle ofrays, the diffraction efficiency is 100%, but actually the diffractionefficiency does not become 100% owing to several factors.

[0027] Next, a method of working a metal die for forming andtransferring diffractiive grooves of a diffractive optical element willbe shown. In FIG. 3, a perspective view of a double or triple spindlesuper-precision lathe is shown. FIG. 4 is a drawing showing a tool forcutting a metal die; FIG. 4(a) is a perspective view of it, FIG. 4(b) isthe front view of the cutting part, and FIG. 4(c) is the side view ofthe cutting part

[0028] In FIG. 3, on a spindle slide table 102 which is supported on abase plate 100 and capable of moving in the Z direction, an air spindle103 is disposed, to support a metal die 50 in a manner capable ofrotation. On the other hand, at this side of the spindle slide table102, a tool table which is capable of moving in the X direction isdisposed, to support a tool 70.

[0029] As the metal die 50 is being rotated by the air spindle 103, thesurface of the metal die 50 corresponding to the diffractive grooves ofan optical element is cut-worked with a diamond tool 70 with a shape ofa bayonet having its corner of the cutting part sharply pointed as shownin FIG. 4. Because it is usually required that the shape error inworking an aspherical shape is not greater than 50 nm, it is moregeneral to carry out the working by using a double spindlesuper-precision lathe which is simpler and easy to do a high-speedworking than a triple spindle type for which the positional adjustmentof the cutting part of a tool is complicated. Accordingly, to the shapeof valleys on the metal die 50 corresponding to diffractive grooves, theshape of the corner of the tool is transferred as it is; therefore, towhat degree the corner of the cutting part of the tool is sharp becomesone of the important factors influencing diffraction efficiency.

[0030] In FIG. 4, the cutting part of the tool is sharply pointed andthe corner of the cutting part converges to a point; however, the cornerof the cutting part of an actual tool has a shape such that the cornerof the rake face has a shape of a minute arc or plane for example, or acomplicated shape produced by a minute chipping at the time ofmanufacturing the tool, and has a size not smaller than several hundredsnm. In this specification, this portion is referred to as the third partof the cutting edge, and the shape on an optical surface cut-formed bythis portion is referred to as the third surface.

[0031]FIG. 5 is a graph showing the lowering of diffraction efficiencyfor a single light-source wavelength in a sawtooth-shaped diffractiveoptical surface of a flat plate, when diffractive grooves are cut-workedby using a tool having the arc-shaped corner of the cutting part inworking the metal die; this graph is prepared by taking the arc radiusof the corner of the cutting part for the abscissa, the diffractionefficiency for the ordinates, and taking three kinds of width (pitch)values of the diffractive grooves 10 μm, 20 μm, and 40 μm in thedirection perpendicular to the optical axis for a parameter. At thecorner radius size of the tool of 10 μm, the diffraction efficiency islowered to 82.3% even for the pitch of the diffractive grooves of 40 μm,to 66.2% for the pitch of 20 μm, and 39.1% for the pitch of 10 μm, whichis not shown in the graph, to make most of the incident light scatteredand the diffraction effect impossible to expect. Even in the case wherethe corner radius size of the tool is so small as 3 μm, the diffractionefficiency is 90.8% for the pitch of 40 μm, 82.3% for the pitch of 20μm, and 65.4% for the pitch of 10 μm, which means that 1/3 of the lightquantity is scattered still. Inversely speaking, in order to make thequantity of scattered light not greater than 10% or 5% by theabove-mentioned criterion, it is necessary that the corner radius of thecutting part of a tool is made to be not greater than 3.5 μm or 1.5 μmfor the pitch of 40 μm, not greater than 1.5 μm or 0.9 μm for the pitchof 20 μm, and not greater than 0.7 μm or 0.3 μm for the pitch of 10 μm,respectively.

[0032] From the above description, it can be understood that, in orderto make the quantity of scattered light to be not greater than 10% or5%, the ratio of the width in the direction perpendicular to the opticalaxis, of the groove portion which cannot be cut to an ideal shape owingto the corner radius of the cutting part of a tool, to the width of thediffractive grooves in the same perpendicular direction is at least notgreater than 10%, or more desirably, not greater than 5%.

[0033] Incidentally, there is an actual situation that, in the casewhere diffraction is utilized for a plurality of light wavelengths asdescribed in the foregoing, diffraction efficiency cannot be made 100%for all the wavelengths used. FIG. 6 is a drawing showing the relationbetween wavelength used, which is taken for the abscissa, anddiffraction efficiency of an optical element, which is taken for theordinate. The curve a shows the diffraction efficiency in the case wherethe depth of the steps of the diffractive grooves is designed to be suchan amount as to make 100% the diffraction efficiency at the wavelength655 nm, which is the wavelength of a light source for a DVD. In thiscase, it is understood that, at the wavelength 785 nm, which is thewavelength of a light source for a CD, the quantity of the transmittedlight is lowered to 91%, even though the loss owing to surfacereflection is omitted.

[0034] On the other hand, the curve b shows the diffraction efficiencyin the case where the depth of the steps of the diffractive grooves isdesigned to be such an amount as to make 100% the diffraction efficiencyat the wavelength to be used for a CD, and at the wavelength to be usedfor a DVD, diffraction efficiency is lowered to a degree of 87.5%, and alarge amount of light quantity loss is produced. Therefore, for adiffractive optical element to be used for a plurality of light-sourcewavelengths, it is used a method such that the designed wavelength isadjusted usually in such a way as to make diffraction efficiency 100% ata wavelength approximately in the middle of the both wavelengths asshown by the curve c, to maintain a fairly satisfactory diffractionefficiency for either of the light-source wavelengths. For the curve c,the depth of steps of the diffractive grooves is designed so as to makediffraction efficiency 100% at the wavelength 720 nm, and diffractionefficiency is maintained to be about 98% for the wavelength to be usedfor a DVD, and about 97% for the wavelength to be used for a CD.

[0035] Accordingly, it should be understood that even if an idealoptical surface can be obtained, in an optical system in which aplurality of light wavelengths are used as described in the above, lightquantity loss of about 3% is inevitably produced for every diffractiveoptical surface. On top of it, because the above-mentioned lowering ofdiffraction efficiency owing to the corner radius of the cutting part ofa tool is generated in the same way as the case of a single wavelengthindependently of these, it is necessary to control the corner radius ofthe cutting part of a tool to be smaller.

[0036] In this case, assuming that diffraction efficiency is not lowerthan 95%, the decrement of diffraction efficiency owing to the cornerradius of the cutting part of a tool must be 2% or under, and the cornerradius of a tool should be 1 μm or under for the pitch 40 μm, 0.5 μm orunder for the pitch 20 μm, and 0.1 μm or under for the pitch 10 μm. Theratio of the width in the direction perpendicular to the optical axis,of the portion which is formed not to-have an ideal shape owing to thesize of the corner of the cutting part to the width of the grooves inthe same direction is generally 8% or under.

[0037] In this specification, the shape of the corner of the cuttingpart of the cutting tool 70 is assumed to be an arc; however, in thecase of an actual tool, the shape of the corner of a tool becomes mostlyas it is formed at the time of making the apex angle by grinding, and ithas not always a shape of an exact arc. However, it is not varied thatthe size of the corner of a tool with respect to the width ofdiffractive grooves influences diffraction efficiency, and it isrequired in order not to lower diffraction efficiency by 2% or more thatthe ratio of the size of corner of a tool to the width of diffractivegrooves is 15% or under as described in the above, or in order to makethe lowering of diffraction efficiency not larger than 1%, it isnecessary to make the proportion of the non-ideal-shaped portion ofdiffractive grooves 8% or under. Further, because the size of the cornerof the cutting part of a tool is about 0.3 μm or so for the bestcondition in the manufacturing process, it is understood that, assumingthe proportion of non-ideal-shaped diffractive grooves is up to 15%, theminimum width of diffractive grooves is 2 μm or so.

[0038] However, an accident that the cutting part of a diamond tool ischipped during the manufacturing of the tool occurs more frequently, thesharper the corner is made; thus, in the case where the corner size ofthe cutting part of a tool is 1 μm or under, the yield of manufacturingtools is lowered sharply. Further, regarding a refracting surfacebetween steps, if the corner of the cutting part of a tool is madesharper, the surface roughness is deteriorated in the case of workingwith the same tool feed; therefore, the amount of the generation ofscattering in this portion increases. Up to this time, the corner sizeof the cutting part of a tool has never been checked in view of such apractical problem, but only it is emphasized that the corner of thecutting part of a tool should be made minute for improving diffractionefficiency.

[0039] Further, in the case where a plurality of light wavelengths areused, because a shape which makes diffraction efficiency 100% for anyone of the wavelengths extremely lowers diffraction efficiency for otherwavelengths, no other shape can be selected than one that makesdiffraction efficiency fairly sufficient for the plural wavelengths;thus, even a shape of diffractive grooves that is ideal in the designingstage does not make diffraction efficiency 100% at the wavelengths used,and the loss of transmitted light quantity of several % owing toscattering is generated. In such a situation, it is necessary to avoidthe loss of transmitted light quantity in an actual optical elementthoroughly, but up to this time, it has never been made definite that,for such an optical element to cope with a plurality of wavelengths, aparticularly careful study is required.

[0040] An optical element set forth in (2) is characterized by it thatthe aforesaid specified optical function is expressed by the followingequations:

N=INT(Ah ² +Bh ⁴ +C),

X(h, N)=h ²/(r _(N)(1+{square root}(1−(1+K _(N))h ² /r _(N) ²)))+A4_(N)h ⁴ +A6_(N) h ⁶ +A8_(N) h ⁸ +A10_(N) h ¹⁰ +ΔN,

[0041] where N denotes the number of a ring-shaped zone of the aforesaiddiffractive grooves, h denotes a height from the optical axis, X denotesa distance from a tangent plane in the direction of the optical axis, rdenotes the radius of the curvature of the Nth ring-shaped zone,K_(N)A4_(N) to A10_(N) are the coefficients of the aspherical surface,and Δ=−λ₀/(n−1) denotes the amount of the shift of the wave front on theoptical axis for 1λ₀. The above equations are noted in p. 92 of“Introduction to Diffractive Optical Elements” (published by OptronicsInc.), and the shape of a cross-section including the optical axis canexpress a sawtooth-shaped diffractive surface. In the above expression,λ₀ may be made the manufacturing wavelength of diffraction ring-shapedzones. In addition, it is possible to use any functions other than theones described in the above, so long as they can express the shape ofthe diffraction surface of an optical element.

[0042] Generally speaking, the pitch of diffractive ring-shaped zones(the position of each of ring-shaped zones) is defined by using a phasedifference function or an optical path difference function. To state itconcretely, the phase difference function Φb is expressed by thefollowing equation described in [M1] with radian taken for the unit, andthe optical path difference function ΦB is expressed by the equationdescribed in [M2] with mm taken for the unit. $\begin{matrix}{\Phi_{b} = {\sum\limits_{i = 0}^{\infty}\quad {b_{2i}h^{2i}}}} & \lbrack{M1}\rbrack \\{\Phi_{B} = {\sum\limits_{i = 0}^{\infty}\quad {B_{2i}h^{2i}}}} & \lbrack{M2}\rbrack\end{matrix}$

[0043] Although the units are different, these two ways of expressionare equivalent in the sense that they both express the pitch ofdiffraction ring-shaped zones. That is, for a blazed wavelength λ (unit:mm), the coefficient of the phase difference function b can be convertedinto the coefficient of optical path difference function B bymultiplying λ/2π to it, and inversely, the coefficient of the opticalpath difference function B is converted into the coefficient of thephase difference function b by multiplying 2π/λ.

[0044] Now, for the simplicity of explanation, a diffractive lensutilizing the first order diffraction light beam will be explained. Inthe case of optical path difference function, a ring-shaped zone iscarved every time when the value of the function exceeds an integralmultiple of the blazed wavelength λ, and in the case of the phasedifference function, a ring-shaped zone is carved every time when thevalue of the function exceeds an integral multiple of 2π.

[0045] For example, it is assumed a lens which is formed of acylindrical-shaped body having diffractive ring-shaped zones carved onthe plane of the object side of the both planes of the cylinder havingno refracting power, and assuming that the blazed wavelength is 0.5μm=0.0005 mm, the second order coefficient of the optical pathdifference function (the second power term) is −0.05 (if it is convertedinto the second order coefficient of the phase difference function, itbecomes −628.3), and the coefficients of other orders are all zero, forthe radius of the first ring-shaped zone, h=0.1 mm, and for the radiusof the second ring-shaped zone, h=0.141 mm. Further, regarding the focallength f of this diffractive lens, it is known that, for the secondorder coefficient of the optical path difference function B2=−0.05,f=−1/(2·B2)=10 mm.

[0046] In the case based on the above-mentioned definition, by makingthe second order coefficient of the phase difference function or the orthe optical path difference function a value not equal to zero, it ispossible to make a lens have a power. Further, by making the coefficientother than the second order one of the phase difference function or theoptical path difference function, for example, the fourth ordercoefficient, the sixth order coefficient, the eighth order coefficient,or the tenth order coefficient a value not equal to zero, it is possibleto control a spherical aberration. In addition, the term “to control” asused in the above description means to correct the spherical aberration,which the portion having a refracting power produces, by producing areverse spherical aberration, or to make the total spherical aberrationhave a desired value.

[0047] An optical element set forth in (3) is characterized by it thatit is a coupling lens of an optical pickup device for use in aninformation recording and/or reproducing apparatus.

[0048] An optical element set forth in (4) is characterized by it thatit is an objective lens which converges a parallel beam coming fromdirection of the optical axis.

[0049] An optical element set forth in (5) is characterized by it thatit is an objective lens which converges a divergent light beam comingfrom the direction of the optical axis.

[0050] An optical element set forth in (6) is characterized by it thatit is a collimator.

[0051] An optical element as set forth in (7) is an optical elementwhich comprises, at least in a part of an optical surface, diffractivegrooves provided with at least a first surface approximately expressedby a specified optical function, and a second surface extending in thedirection crossing said first surface, and is capable of transmitting alight beam from a single light source or light beams from a plurality oflight sources having different wavelengths, wherein the Rz value ofsurface roughness of said first surface is not greater than {fraction(1/10)} of the used wavelengths of said light sources; therefore, thequantity of transmitted light can be sufficiently secured by suppressingscattering of an incident light beam.

[0052] In addition, the minimum value of the Rz value of the surfaceroughness of said first surface is not smaller than {fraction (1/1000)}of the used wavelengths of said light sources. Moreover, these Rz valuesof surface roughness are values defined by JIS B0601-1994 (ISO 4287).

[0053] In the case where a metal die for an optical surface is worked bya lathe with a cutting tool having a pointed corner, the condition oftool feeding influences the surface roughness of the optical surface tobe generated to a large extent. Accordingly, even though the pitch, andthe ridgelines of the peaks and valleys are approximately ideal-shapedsimply, and the diffraction efficiency is close to ideal, a largesurface roughness of the transmitting surface would scatter an incidentbundle of rays to cause the transmitted light quantity to decrease. Thescattering owing to surface roughness is inversely proportional to thefourth power of wavelength if it is regarded as Rayleigh scattering;therefore, if the wavelength of a light source used is made shorter,scattering increases sharply even for the same surface roughness, toproduce a large loss of transmitted light quantity. Hence, it isreasonable to specify the surface roughness of a transmitting opticalsurface in accordance with the wavelength to be used, and if the Rzvalue of surface roughness is not larger than {fraction (1/10)} of thewavelength, scattering exceeding 1% is not generated. The Rz value ofsurface roughness is a value calculated by subtracting the values of thelowest 5 valley points from the values of the highest 5 peak pointsrespectively, and averaging out the differences, and is a reliable PVvalue (maximum-minimum value) which is hard to be influenced by a noiseor an abnormal point by averaging out.

[0054] Further, in a cut-working with a diamond tool, it is generallyknown that a damaged layer having a depth of about 1 nm on the workedsurface is formed by the cutting force during working, and in thisdamaged layer, because the arrangement of atoms is varied from the statebefore working, it is very difficult to control the surface roughness ofworking under the thickness of this damaged layer. Hence, the lowestlimit value of the Rz-value of surface roughness is about {fraction(1/1000)} in terms of the wavelength to be used.

[0055] In an optical element set forth in (8), the aforesaid specifiedoptical function is characterized by it that it is expressed by thefollowing equations:

N=INT(Ah ² +Bh ⁴ +C)

X(h, N)=h ²/(r _(N)(1+{square root}(1−(1+K _(N))h ² /r _(N) ²)))+A4_(N)h ⁴ +A6_(N) h ⁶ +A8_(N) h ⁸ +A10_(N) h ¹⁰ +ΔN,

[0056] where N denotes the number of a ring-shaped zone of the aforesaiddiffractive grooves, h denotes a height from the optical axis, X denotesa distance from a tangent plane in the direction of the optical axis, rdenotes the radius of the curvature of the Nth ring-shaped zone,K_(N)A4_(N) to A10_(N) are the coefficients of the aspherical surface,and Δ=−λ₀/(n<1) denotes the amount of the shift of the wave front on theoptical axis for 1λ₀.

[0057] In an optical element set forth in (9), the aforesaid secondsurface is characterized by it that it is parallel to the optical axiswith an angular error not greater than 1°.

[0058] An optical element set forth in (10) is an optical element as setforth in any one of structures (7) to (9) characterized by it that it isa coupling lens of an optical pickup device for use in an informationrecording and/or reproducing apparatus.

[0059] An optical element set forth in (11) is characterized by it thatit is an objective lens which converges a parallel light beam comingfrom the direction of the optical axis.

[0060] An optical element set forth in (12) is characterized by it thatit is an objective lens which converges a divergent light beam comingfrom the direction of the optical axis.

[0061] An optical element set forth in (13) is characterized by it thatit is a collimator.

[0062] A metal die set forth in (14) is a metal die which comprises, atleast in a part of an optical surface, diffractive grooves provided withat least a first surface approximately expressed by a specified opticalfunction, and a second surface extending in the direction crossing saidfirst surface, and is used in forming an optical element capable oftransmitting a light beam by molding, wherein the surface of said metaldie corresponding to at least said first surface of said optical elementis formed by rotary cut-working, and the amount of feed of a cuttingtool in the radius direction at the time of working falls within a rangefrom 0.1 μm to 1 μm per one rotation of said metal die; therefore, thequantity of transmitted light can be sufficiently secured by suppressingscattering of an incident light beam.

[0063]FIG. 7 are drawings showing the relation between setting positionsof a metal die and a tool at the time of cut-working. The Rz value ofsurface roughness that is obtained when a refracting optical surface iscut-worked by an actual cut-working is varied in accordance with the wayof setting a tool as shown in FIG. 7. FIG. 7(a) shows the case of anoffset angle of 0° where a tool is set in such a way that the centralline of the tool becomes parallel to the optical axis of the opticalsurface of the metal die; in this case, the step section of diffractivegrooves become conical around the optical axis, and in particular, foran infinite incident bundle of rays, optically unnecessary part isproduced. FIG. 7(b) shows the case where a tool is set with an offsetangle of α/2 to right in such a way that the one of the flanks makingthe apex angle α of the tool becomes parallel to the optical axis inorder to make the step section of the diffractive grooves parallel tothe optical axis. As clearly understood from the both drawings, in therelation shown in FIG. 7(a), the Rz value is theoretically P/2 tan {α/2}for an amount of feed per one rotation of the metal die P (called a feedrate also), and in the relation shown in FIG. 7(b), Rz P/tan α is given.In this case, if the tool apex angle α is as small as 10° or under, thedifference between the Rz values for both cases can be regardedapproximately as zero, because 2 tan(α/2)≅2×α/2=α≅tan α.

[0064] However, such a small apex angle of a tool is actually notgeneral, because it causes chipping of the cutting part frequently tooccur during manufacturing of a tool, and breakage of the cutting partduring cut-working is easy to be generated. Further, it does not loweralso the Rz value itself. Usually, it is general that the apex angle ofa tool is determined to be about 30 to 40° with the above-mentionedthings taken into consideration, and the Rz values for these cases arecompared in the table shown in FIG. 7(c). It is understood that surfaceroughness is improved for the relation of FIG. 7(b) by 7.5% at the toolapex angle 30° and almost 15% at the tool apex angle 40° than the caseshown in FIG. 7(a). Further, to state it inversely, for obtaining thesame value of the surface roughness Rz, the tool setting shown in FIG.7(b) can perform cut-working with a feed rate P faster by 7.5 to 15%than the relation of FIG. 7(a); therefore, working of a die can beperformed with a higher speed and better efficiency.

[0065] Now, surface roughness Rz will be explained. In an example of anobjective lens for a pickup device employing a conventional refractinglens or a collimator, for the used wavelength 650 nm, the surfaceroughness Rz of an optical surface was about 50 nm, and the loss oflight quantity of the formed lens owing to the surface scattering was 1%or under. From this fact, it is understood that the loss of lightquantity owing to Rayleigh scattering can be reduced to an almostnegligible degree, if the surface roughness Rz of a lens which is formedby an optical surface of a metal die cut-worked with a diamond tool.

[0066] Further, in order to obtain a better surface roughness, it isappropriate to make small the above-mentioned amount of feeding a toolper one rotation of an optical surface of a metal die (feed rate) P, bylowering the speed of feeding the tool during the cut-working of anoptical surface. However, to make the feed rate P small means to prolongthe time for cut-working, and about {fraction (1/10)} times of thepresent feed rate is practically a limit for the reason of productivity.Because the surface roughness value Rz of an optical element which iscut-worked with a tool having a pointed corner is proportional to thefeed rate P as shown in FIG. 7(c), the Rz value obtained by acut-working in this condition is about {fraction (1/100)} of thewavelength of the used light source, as it is {fraction (1/10)} of theabove-mentioned value. To summarize the above-mentioned, in order toeliminate the influence of light quantity loss owing to Rayleighscattering, only it is necessary to make Rz value {fraction (1/10)} orunder of the wavelength of the used light source, and practically it isdesirable to make it not smaller than {fraction (1/100)} at the sametime.

[0067] Incidentally, in the cut-working of the optical surface of ametal die with a tool, if it is supposed to be obtained, the feed rate Pto satisfy the condition for making the Rz value fall within a rangefrom {fraction (1/1000)} to {fraction (1/10)} of the wavelength of theused light source as described in the above, assuming that thewavelength of the used light source is 650 nm, and a tool having theapex angle of the cutting part 30° is set at an offset angle of 15° asshown in FIG. 7(b), the feed rate falls within a range from 3.75 nm/revto 37.5 nm/rev This is a value in the case where the corner of thecutting part of the tool makes a perfect apex, and it is understood thatan extremely lower feed rate is necessary as compared with a usual feedrate which is from 2 to 4 μm/rev Because such a low feed rate valuegives too low a productivity in the actual working of metal dies, it isof no practical use in the case where a mass of metal dies arenecessary.

[0068] However, in the case of the corner of the cutting part of anactual straight turning tool, there is a limit in making it sharp forthe reasons of yield in manufacturing and efficiency, to result in aminute round-shaped corner in most cases. In some cases, even chamferingis done by cutting off the corner of the cutting part intentionally inorder to prevent breakage. As described in the above, in a situationsuch that there is a minute arc at the corner of the cutting part, thefeed rate value can be remarkably improved as described below, with thesurface roughness of working suppressed to a low value.

[0069] The following relation is known between the feed rate P in thecase where corner radius R is given to the corner of the cutting partand the surface roughness Rz of working:

Rz=R(1−cos φ), where φ=sin⁻¹ (P/2R)  (eq.1).

[0070] On the basis of this, the values of the feed rate P, which areobtained for Rz values at λ=650 nm, including the case where the cornerof the cutting part is an apex, are shown in the following [Table 1].For the corner radius R of the cutting part, diffraction efficiency isimproved sharply for R values of 3 μm or under as shown in FIG. 5 too,and for R values of 1 μm or under, the improvement of diffractionefficiency accompanied by its getting further minute becomes gentle.Therefore, in this invention, it is specified the case where the cornerof the cutting part lies at a distance from the position of the virtualapex point within a range from 0.1 μm to 3 μm with the cases where theapex angle α is up to 90° taken into consideration, including the casewhere the corner of the cutting part is not round. On the other hand,from the practical view point to reduce the lowering of yield owing tochipping during manufacturing of a tool and the wear by grinding,efficiency, etc., and chipping during actual cut-working and breakage ofthe corner of the cutting part, it is said that the limit of the cornerradius R of the cutting part is about 0.3 μm; therefore, it can be saidthat the range of the corner radius R of the cutting part from 0.3 μm to0.5 μm is an optimum range to keep diffraction efficiency high and tomake a stable supply and working possible. Assuming that the apex angleof the cutting part has a general value, which is about 40°, includingalso the above-mentioned case where the corner of the cutting part isnot round, for a more desirable range, it can be considered that thecorner of the cutting part lies at a distance from the virtual apexpoint falling within a range from 0.2 μm to 1.5 μm. The following [Table1] shows the values of the feed rate P which are calculated for theabove-mentioned range with the corner radius R of the cutting partvaried. TABLE 1 Edge end R Rz = λ/10 Rz = λ/100 R = 0  37.5 nm/rev  3.8nm/rev R = 0.1 μm 137.0 nm/rev  57.7 nm/rev R = 0.3 μm 241.0 nm/rev111.0 nm/rev R = 0.5 μm 361.0 nm/rev 147.0 nm.rev

[0071] Now, if the case where the corner radius R of the cutting part is0.3 μm, which is a limit value in manufacturing a tool, is compared withthe case where the corner radius R is zero, that is, an ideal apex, forobtaining the surface roughness Rz value λ/1000 (6.5 nm), the differencein feed rate is more than 15 times, and this as itself directlyindicates that the corner of the cutting part being made 0.3 μm canimprove the efficiency of cut-working of a metal die by more than 15times. Further, it is understood by this that the corner radius R of thecutting part 0.3 μm means not only the limit from the view point of theyield of manufacturing and the efficiency, but also the limit ofminuteness in cut-working for the reasons of suppressing Rayleighscattering and securing a practical productivity. To summarize theabove-mentioned things, in the case where an optical surface of a metaldie is cut-worked with a straight turning tool, it is ideal to determinethe feed rate in accordance with the size of the corner radius R of thecutting part, but it is necessary to make it at least 1 μm/rev or underand it is desirable to make it 100 nm/rev or over.

[0072] An equivalent corner radius R of the cutting part is obtainedfrom a distance D from the apex of the cutting part to a positionincluding the whole corner edge. In respect of a corner edge of astraight turning tool which lies within the distance D from the virtualapex of the cutting part, the shape of the corner edge is not always anarc; however, by substituting for the shape an equivalent arc whose sizeis not so much different from the size of the front edge of the cuttingpart for generalization, a value of criterion for a surface roughness Rzof working and a feed rate which is a condition of cutting can beobtained. Now, this equivalent corner radius R of the cutting part is tobe obtained by the following equation:

R=D·tan (α/2)  (eq.2),

[0073] where α denotes the apex angle of the cutting part.

[0074] In a metal die set forth in (15), the aforesaid second surface ischaracterized by it that it is parallel to the optical axis with anangular error not greater than 1°.

[0075] An optical element set forth in (15) is characterized by it thatsaid optical element is formed by injection molding or by injectioncompression molding using a metal die as set forth in (14) or (15).

[0076] In an optical element set forth in (17), the aforesaid specifiedoptical function is characterized by it that it is expressed by thefollowing equations:

N=INT(Ah ² +Bh ⁴ +C),

X(h, N)=h ²/(r _(N)(1+{square root}(1−(1+K _(N))h² /r _(N) ²)))+A4_(N) h⁴ +A6_(N) h ⁶ +A8_(N) h ⁸ +A10_(N) h ¹⁰ +ΔN,

[0077] where N denotes the number of a ring-shaped zone of the aforesaiddiffractive grooves, h denotes a height from the optical axis, X denotesa distance from a tangent plane in the direction of the optical axis, rdenotes the radius of the curvature of the Nth ring-shaped zone,K_(N)A4_(N) to A10_(N) are the coefficients of the aspherical surface,and Δ=−λ₀/(n−1) denotes the amount of the shift of the wave front on theoptical axis for 1λ₀.

[0078] An optical element set forth in (18) is characterized by it thatit is a coupling lens of an optical pickup device for use in aninformation recording and/or reproducing apparatus.

[0079] An optical element set forth in (19) is characterized by it thatit is an objective lens which converges a parallel light beam comingfrom the direction of the optical axis.

[0080] An optical element set forth in (20) is characterized by it thatit is an objective lens which converges a divergent light beam comingfrom the direction of the optical axis.

[0081] An optical element set forth in (21) is characterized by it thatit is a collimator.

[0082] A tool set forth in (22) is a tool for cutting a metal die to beused in forming by molding an optical element which comprises, at leastin a part of an optical surface, diffractive grooves provided with afirst surface expressed approximately by a specified optical function, asecond surface extending in the direction crossing said first surface,and a third surface connecting said first surface and said secondsurface, and is capable of transmitting light, wherein at least a partof the surface of said metal die is formed by rotary cut-working usingsaid tool, the rake face of said tool, which is opposite to the rotatingdirection of said metal die during said rotary cut-working, is outlinedby a first part of the cutting edge which cut-forms the surface of saidmetal die corresponding to said second surface of said optical element,a second part of the cutting edge extending in the direction crossingsaid first part of the cutting edge, and a third part of the cuttingedge which cut-forms the surface of said metal die corresponding to saidthird surface of said optical element, and the distance from theintersecting point of an extended line of said first part of the cuttingedge and an extended line of said second part of the cutting edge tosaid third part of the cutting edge is from 0.1 μm to 3 μm; therefore,by an optical element formed by a metal die which is cut with theabove-mentioned tool, transmitted light quantity can be sufficientlysecured by suppressing scattering of an incident light.

[0083] This invention will be explained in more detail by referring tothe drawings. FIG. 8 is a drawing showing the relation between a tool 70and a metal die 50 during cutting by a lathe. In FIG. 8, the metal die50 has its three surfaces formed with the tool 70, that is, a firstsurface 11′ corresponding to the first surface of diffractive grooves ofan optical element which is expressed approximately by a specifiedoptical function, a second surface 12′ corresponding to the secondsurface which is approximately parallel to the optical axis, and a thirdsurface 13′ corresponding to the third surface connecting these. In thisworking, the rake face 74 of the tool 70 which is opposite to therotating direction of the metal die 50, is outlined by a first part ofthe cutting edge 71 which cut-forms the surface 12′ of the metal die 50,a second part of the cutting edge 72 extending in the direction crossingthe first part of the cutting edge 71, and a third part of the cuttingedge 73 which cut-forms the surface 13′ of the metal die, and thedistance Δ3 from the intersecting point of an extended line of the firstpart of the cutting edge 71 and an extended line of the second part ofthe cutting edge 72 to the part of the cutting edge 73 falls within arange from 0.1 μm to 3 μm; therefore, the surface 13′ of the metal die50 is controlled to be small, and by an optical element formed by themetal die 50 which is cut with this tool 70, transmitted light quantitycan be sufficiently secured by suppressing scattering of an incidentlight.

[0084] A metal die set forth in (23) is characterized by it that it isworked with a tool as set forth in (22).

[0085] In a metal die set forth in (24), the aforesaid second surface ischaracterized by it that it is parallel to the optical axis with anangular error not greater than 1°.

[0086] An optical element set forth in (25) is characterized by it thatit is formed by injection molding or by injection compression moldingusing a metal die as set forth in (23) or (24).

[0087] In an optical element set forth in (26), the aforesaid specifiedoptical function is characterized by it that it is expressed by thefollowing equations:

N=INT(Ah ² +Bh ⁴ +C),

X(h, N)=h ²/(r _(N)(1+{square root}(1−(1+K _(N))h² /r _(N) ²)))+A4Nh ⁴+A6_(N) h ⁶ +A8_(N) h ⁸ +A10_(N) h ¹⁰ +ΔN,

[0088] where N denotes the number of a ring-shaped zone of the aforesaiddiffractive grooves, h denotes a height from the optical axis, X denotesa distance from a tangent plane in the direction of the optical axis, rdenotes the radius of the curvature of the Nth ring-shaped zone,K_(N)A4_(N) to A10_(N) are the coefficients of the aspherical surface,and Δ=−λ₀/(n−1) denotes the amount of the shift of the wave front on theoptical axis for 1λ₀.

[0089] An optical element set forth in (27) is characterized by it thatit is a coupling lens of an optical pickup device for use in aninformation recording and/or reproducing apparatus.

[0090] An optical element set forth in (28) is characterized by it thatit is an objective lens which converges a parallel light beam comingfrom the direction of the optical axis.

[0091] An optical element set forth in (29) is characterized by it thatit is an objective lens which converges a divergent light beam comingfrom the direction of the optical axis.

[0092] A tool set forth in (31) is a tool for cutting a metal die to beused in forming by molding an optical element which comprises, at leastin a part of an optical surface, diffractive grooves provided with afirst surface expressed approximately by a specified optical function, asecond surface extending in the direction crossing said first surface,and a third surface connecting said first surface and said secondsurface, and is capable of transmitting light, wherein at least a partof the surface of said metal die is formed by rotary cut-working usingsaid tool, the rake face of said tool, which is opposite to the rotatingdirection of said metal die during said rotary cut-working, is outlinedby a first part of the cutting edge which cut-forms the surface of saidmetal die corresponding to said second surface of said optical element,a second part of the cutting edge extending in the direction crossingsaid first part of the cutting edge, and a third part of the cuttingedge which cut-forms the surface of said metal die corresponding to saidthird surface of said optical element, and the angle α, which is made bysaid first part of the cutting edge and said second part of the cuttingedge, is not smaller than 5° and satisfies an inequityθmax≦(90−(α/2+S))°, where θmax denotes the maximum normal angle of saidmetal die corresponding to said optical surface, and S denotes a setangle of the tool against the optical axis (what is called an offsetangle); therefore, it never occurs that a metal die is subjected to aninterference by a tool, which makes it possible to manufacture anoptical element having a more suitable shape.

[0093] In particular, because the curvature of the optical surface has atendency to become stronger in the case of a metal die for forming ahigh-NA lens, in some cases the normal angle θ (the angle made by anormal and the optical axis) of the optical surface shape becomes verylarge in the neighborhood of the outermost circumference of the opticalsurface shape 50 a, and in this case, if a conventional tool iscarelessly used, it provably occurs that a tool interference (anaccident in which a part of a tool that is not a cutting edge engageswith the metal die) occurs. In the following, examples of the toolinterference which have been heretofore produced easily will beexplained.

[0094] For the first mode of the tool interference, such an example asdescribed below can be cited. In order not to lower diffractionefficiency, it is necessary that the step section of the diffractivegrooves (the second surface 12 as shown in FIG. 2) are parallel to theincident bundle of rays. Hence, in the case where the incident bundle ofrays is an infinite light beam, the step section make a cylindricalsurface parallel to the optical axis. Further, in the case where theincident bundle of rays is a divergent one, a conical shape such that astep section overhangs to a degree not to produce a shadow for anincident bundle of rays is ideal; However, this shape has an undercutsection at the time of forming a lens, and a problem that an opticalelement which has been injection-molded sticks to the metal die andcannot be released is produced. For that reason, it is desirable thatthe step section is parallel to the optical axis and cylindrical forthese incident bundle of rays.

[0095] However, in cut-working a metal die for molding with a tool, asshown in FIG. 7(b), it is necessary to set the tool with an inclinationto the direction of the outer circumference by an offset angle S (anangle equal to ½ of the apex angle α, for example). Accordingly,elbowroom for the tool is 90°−(α/2+S) only, and in order that the metaldie may not interfere the tool during cut-working, a normal angle atanywhere on the optical surface must be smaller than this value. On topof it, in an actual optical element, in order that a flange portion forfixing the element may be provided integrally at the outer side in theradial direction of the optical surface, it often occurs that theoptical surface is required to have a shape extended to the fartheroutside of the effective diameter; therefore, it is understood that,also in this extended portion which does not actually transmit a bundleof rays, the angle α must be not smaller than 5° and satisfy an inequityθmax≦(90−(α/2+S))°, where S denotes a set angle of the tool against theoptical axis. In addition, “an offset angle of a tool” means an anglemade by a line which bisects equally the apex angle of the cutting partand the optical axis of the optical surface to be cut-worked.

[0096] Accordingly, if the shape function of a diffractive opticalsurface to be worked is known beforehand, the normal angle θ is knownfrom its differential values; therefore, if the maximum normal angleθmax in the range of working is obtained, the apex angle αmax to becomea limit up to which no tool interference occurs is obtained from theabove inequality, and a desired shape can be safely cut-worked. However,if the apex angle of a tool is made too small., the yield inmanufacturing the tool is lowered, which makes the price higher andlowers the stiffness; therefore, an accident such as “bibiri” andbreakage is likely to occur. For that reason, it can be said that adegree of 10° or so for the apex is a practical limit as a tool for ametal die to mold an optical element. The offset angle for this apexangle value should be 5° or over in order to make the step section ofdiffractive grooves parallel to the optical axis.

[0097] A metal die set forth in (32) is characterized by it that it isworked with a tool as set forth in (31).

[0098] A metal die set forth in (33) is characterized by it that theaforesaid second surface is parallel to the optical axis with an angularerror not greater than 1°.

[0099] A metal die set forth in (34) is characterized by it that groovescorresponding to the aforesaid diffractive grooves of the aforesaidoptical element are formed in an area for which the value of theaforesaid maximum normal angle θmax falls within a range from 40° to70°.

[0100] An optical element set forth in (35) is characterized by it thatit is formed by injection molding or by injection compressing moldingusing a metal die as set forth in any one of structures (32) to (34).

[0101] In an optical element set forth in (36), the aforesaid specifiedoptical function is characterized by it that it is expressed by thefollowing equations:

N=INT(Ah ² +Bh ⁴ +C),

X(h, N)=h ²/(r _(N)(1+{square root}(1−(1+K _(N))h ² /r _(N) ²)))+A4_(N)h ⁴ +A6_(N) h ⁶ +A8_(N) h ⁸ +A10_(N) h ¹⁰ +ΔN,

[0102] where N denotes the number of a ring-shaped zone of the aforesaiddiffractive grooves, h denotes a height from the optical axis, X denotesa distance from a tangent plane in the direction of the optical axis, rdenotes the radius of the curvature of the Nth ring-shaped zone,K_(N)A4_(N) to A10_(N) are the coefficients of the aspherical surface,and Δ=−λ₀/(n−1) denotes the amount of the shift of the wave front on theoptical axis for 1λ₀.

[0103] An optical element set forth in (37) is characterized by it thatit is a coupling lens of an optical pickup device for use in aninformation recording and/or reproducing apparatus.

[0104] An optical element set forth in (38) is characterized by it thatit is an objective lens which converges a parallel light beam comingfrom the direction of the optical axis.

[0105] An optical element set forth in (39) is characterized by it thatit is an objective lens which converges a divergent light beam comingfrom the direction of the optical axis.

[0106] An optical element set forth in (40) is characterized by it thatit is a collimator.

[0107] A tool set forth in (31) is a tool for cutting a metal die to beused in forming by molding an optical element which comprises, at leastin a part of an optical surface, diffractive grooves provided with afirst surface expressed approximately by a specified optical function, asecond surface extending in the direction crossing said first surface,and a third surface connecting said first surface and said secondsurface, and is capable of transmitting light, wherein at least a partof the surface of said metal die is formed by rotary cut-working usingsaid tool, the rake face of said tool, which is opposite to the rotatingdirection of said metal die during said rotary cut-working, is outlinedby a first part of the cutting edge which cut-forms the surface of saidmetal die corresponding to said second surface of said optical element,a second part of the cutting edge extending in the direction crossingsaid first part of the cutting edge, and a third part of the cuttingedge which cut-forms the surface of said metal die corresponding to saidthird surface of said optical element, in respect of a first flank whichmakes up said first part of the cutting edge with said rake face, and asecond flank which makes up said second part of the cutting edge withsaid rake face, the inclination angle of said first flank against saidrake face and the inclination angle of said second flank against saidrake face is different from each other, and the difference falls withina range from 1° to 20°; therefore, it never occurs that a metal die issubjected to interference by a tool, which makes it possible tomanufacture an optical element having a more suitable shape. If thedifference is less than 1°, the effect is little, and if it exceeds 20°,manufacturing of a tool becomes difficult. In addition, the both anglesof inclination mean respectively an angle made by said first flankagainst a virtual plane perpendicular to said rake face at the firstpart of the cutting edge and an angle made by said second flank againsta virtual plane perpendicular to said rake face at the second part ofthe cutting edge.

[0108] The second mode of the tool interference will be explained. Theshape of the diamond chip of the cutting part of a conventional toolforms, as shown in FIG. 4, a first clearance angle β1 by it that theflanks 75 and 76 making up the apex angle intersect each other with anangle deviated by several degrees from the rectangle against the rakeface. The tool is designed in such a manner that, by forming the secondclearance face 77 further, it never occurs that the flanks 75 and 76extend long toward lower direction to such a degree as to interfere theshape of the optical surface of a metal die. However, the firstclearance angle β1 has a limit of about 10° at the maximum because ofgeneration of chips etc. during manufacturing of the tool, and theangles of inclination of the flanks 75 and 76 have a limit of severaldegrees, which depends on the apex angle α.

[0109] In a conventional tool, the inclination angles of the flanks 75and 76 have been taken as equal for both left and right sides, whichmakes the shape of the edge symmetric in respect to left-and-rightdirection. Therefore, the inclination angle of the flanks is uniquelydetermined if the apex angle α is determined, and it has been put intopractice that, in the case where the ridgeline of one of the flanks 75and 76 and the second clearance face 77 generates tool interference, theangle β2 of the second clearance face 77 is usually made to take a valuefalling within a range from 40° to near 50°. It is a matter of coursethat this lowered the strength of the cutting part and increased thefrequency of generation of “bibiri” or chips during working, which madedifficult the working of a high-precision diffractive optical surfaceshape.

[0110] Therefore, the inventors found out that, in order to cut-work anideal diffractive optical surface shape, if a tool is set in such amanner as shown in FIG. 7(b), in respect of the flanks in the innercircumferential side, the inclination angle 0° produces no problem atall. Accordingly, it has been found out that, because the inclinationangle for the flanks in the outer circumferential side where a toolinterference occurs provably can be increased to a value near two times,and owing to this, the ridgelines of the flanks 75 and 76 and the secondclearance face 77 retracts more toward the center of the tool, withoutlowering the strength of an edge, and also without lowering theefficiency in manufacturing, a tool interference can be avoided.

[0111] A metal die set forth in (42) is characterized by it that it isworked with a tool as set forth in (41).

[0112] A metal die set forth in (43) is characterized by it that theaforesaid second surface is parallel to the optical axis with an angularerror not greater than 1°.

[0113] An optical element set forth in (44) is characterized by it thatit is formed by injection molding or by injection compression moldingusing a metal die as set forth in (43).

[0114] An optical element set forth in (45) is characterized by it thatthe aforesaid specified optical function is expressed by the followingequations:

N=INT(Ah ² +Bh ⁴ +C),

X(h, N)=h ²/(r _(N)(1+{square root}(1−(1+K _(N))h² /r _(N) ²)))+A4_(N) h⁴ +A6_(N) h ⁶ +A8_(N) h ⁸ +A10_(N) h ¹⁰ +ΔN,

[0115] where N denotes the number of a ring-shaped zone of the aforesaiddiffractive grooves, h denotes a height from the optical axis, X denotesa distance from a tangent plane in the direction of the optical axis, rdenotes the radius of the curvature of the Nth ring-shaped zone,K_(N)A4_(N) to A10_(N) are the coefficients of the aspherical surface,and Δ=−λ₀/(n−1) denotes the amount of the shift of the wave front on theoptical axis for 1λ₀.

[0116] An optical element set forth in (46) is characterized by it thatit is a coupling lens of an optical pickup device for use in aninformation recording and/or reproducing apparatus.

[0117] An optical element set forth in (47) is characterized by it thatit is an objective lens which converges a parallel light beam comingfrom the direction of the optical axis.

[0118] An optical element set forth in (48) is characterized by it thatit is an objective lens which converges a divergent light beam comingfrom the direction of the optical axis.

[0119] An optical element set forth in (49) is characterized by it thatit is a collimator.

[0120] A tool set forth in (31) is a tool for cutting a metal die to beused in forming by molding an optical element which comprises, at leastin a part of an optical surface, diffractive grooves provided with afirst surface expressed approximately by a specified optical function, asecond surface extending in the direction crossing said first surface,and a third surface connecting said first surface and said secondsurface, and is capable of transmitting light, wherein at least a partof the surface of said metal die is formed by rotary cut-working usingsaid tool, the rake face of said tool, which is opposite to the rotatingdirection of said metal die during said rotary cut-working, is outlinedby a first part of the cutting edge which cut-forms the surface of saidmetal die corresponding to said second surface of said optical element,a second part of the cutting edge extending in the direction crossingsaid first part of the cutting edge, and a third part of the cuttingedge which cut-forms the surface of said metal die corresponding to saidthird surface of said optical element, in respect of a first flankswhich makes up said first part of the cutting edge with said rake face,and a second flanks which makes up said second part of the cutting edgewith said rake face, at least one of said flanks has a first inclinationangle against said rake face, making a first clearance angle with anintersecting line of said first flank and said second flank, at leastone of said first flank and said second flank further has a secondinclination angle against said rake face, and at least, the flank havingthis second inclination angle and the other flank forms an intersectingline, which makes a second clearance angle; therefore, it never occursthat a metal die is subjected to an interference by a tool, which makesit possible to manufacture an optical element having a more suitableshape.

[0121] In order to avoid the tool interference more certainly, theinventors propose a tool having a completely new design. FIG. 10 is aperspective view of such a new tool according to this invention. In FIG.10, the flank 75′ of a tool 70′ is composed of the upper flank 75 a′ andthe lower flank 75 b′, and in the case where the inclination angle ofthe upper flank 75 a′ is, for example, 5°, it is desirable that thesecond inclination angle of the lower flank 75 b′ is a value exceeding5°.

[0122] In this way, by making the inclination angle of the flank 75′ notof a single stage only, but of double stages, to form a second clearanceangle β2 by the mutual intersection of the flanks owing to thisinclination angle of this second stage, the above-mentioned secondclearance face can be omitted. Owing to this, because the flank 75′ hasits portion of the first inclination angle made narrow as the thicknessof the portion of the tool forming the first clearance angle andswitches over to the portion of the second inclination angle to form alarge second clearance angle β2, the tool interference can be avoidedwith a greater stride as compared with the conventional one. Further,the portion of the edge thickness corresponding to the first clearanceangle β1, which actually has a cutting edge, has completely the sameshape as a conventional one, it can be prevented that the strength ofthe corner edge is extremely lowered.

[0123] Further, it has a shape capable of corresponding to theabove-mentioned asymmetric inclination angles of side faces; therefor,by combining these factors, it is possible to cut-work a metal die foran optical surface having an extremely [small] large curvature or ahigh-NA lens with a sufficient elbowroom and strength.

[0124] A metal die set forth in (51) is characterized by it that it isworked with a tool as set forth in (50).

[0125] In a metal die set forth in (52), the aforesaid second surface ischaracterized by it that it is parallel to the optical axis with anangular error not greater than 1°.

[0126] An optical element set forth in (53) is characterized by it thatit is formed by injection molding or injection compression molding usinga metal die as set forth in (52).

[0127] In an optical element set forth in (36), the aforesaid specifiedoptical function is characterized by it that it is expressed by thefollowing equations:

N=INT(Ah ² +Bh ⁴ +C),

X(h, N)=h ²/(r _(N)(1+{square root}(1−(1+K _(N))h ² /r _(N) ²)))+A4_(N)h ⁴ +A6_(N) h ⁶ +A8_(N) h ⁸ +A10_(N) h ¹⁰ +ΔN,

[0128] where N denotes the number of a ring-shaped zone of the aforesaiddiffractive grooves, h denotes a height from the optical axis, X denotesa distance from a tangent plane in the direction of the optical axis, rdenotes the radius of the curvature of the Nth ring-shaped zone,K_(N)A4_(N) to A10_(N) are the coefficients of the aspherical surface,and Δ=−λ₀/(n−1) denotes the amount of the shift of the wave front on theoptical axis for 1λ₀.

[0129] An optical element set forth in (55) is characterized by it thatit is a coupling lens of an optical pickup device for use in aninformation recording and/or reproducing apparatus.

[0130] An optical element set forth in (56) is characterized by it thatit is an objective lens which converges a parallel light beam comingfrom the direction of the optical axis.

[0131] An optical element set forth in (57) is characterized by it thatit is an objective lens which converges a divergent light beam comingfrom the direction of the optical axis.

[0132] An optical element set forth in (58) is characterized by it thatit is a collimator.

[0133] The term “diffractive grooves” as used in this specificationmeans grooves of a relief which is provided on a surface of a lens andmade to have a function to converge or diverge a bundle of rays bydiffraction. For the shape of the relief, for example, it is known ashape which is formed as nearly concentric circular ring-shaped zonesaround the optical axis, which has a sawtooth-shaped cross-section asseen at a plane including the optical axis; such a shape is included init.

[0134] In this specification, the term “an objective lens” denotes, inits narrower sense, a single lens having a light-converging functionwhich is arranged opposite to an optical information recording medium atthe most nearest side of it in a state in which an optical pickup deviceis loaded with an optical information recording medium, or in a broadersense, a lens group capable of moving at least in the direction of theoptical axis by an actuator together with that single lens. In the abovedescription, the lens group denotes at least a single lens or more (twolenses, for example). Hence, in this specification, the numericalaperture NA of an objective lens of the side facing an opticalinformation recording medium (the image side) denotes the numericalaperture NA of a lens surface which is positioned nearest to and facingthe optical information recording medium. Further, in thisspecification, the required numerical aperture NA denotes a numericalaperture specified in the standard of each optical information recordingmedium, or a numerical aperture of an objective lens having adiffraction limit performance capable of obtaining a spot diameter whichis required for recording or reproducing information for each opticalinformation recording medium, in accordance with the wavelength of thelight source used.

[0135] In this specification, an optical information recording mediummeans, for example, an optical disk of a CD type such as a CD-R, aCD-RW, a CD-Video, and a CD-ROM, or an optical disk of a DVD type suchas a DVD-ROM, a DVD-RAM, a DVD-R, a DVD-RW, and a DVD-Video.

[0136] In the following, examples of practice of this invention will beexplained. In addition, in respect of an offset angle, there are a casewhere a tool is deflected to left and a case where a tool is deflectedto right; hence for these cases, it is referred to as, for example, anoffset angle of 20° to left, and an offset angle of 20° to rightrespectively. In the following examples of practice, a tool is deflectedto left.

EXAMPLE OF PRACTICE 1

[0137] The corner of the cutting part of a tool (hereinafter referred toas a straight turning tool) having an apex angle of 40° of the cuttingpart was found to have an arc-shape with a length of the chordapproximately 1 μm by an observation using an optical microscope with800 times of magnification. Accordingly, the shape of the corner of thecutting part was regarded as an arc of radius 0.5 μm. In this case, thedistance from the virtual apex of the edge to the end point of the arcwas 0.5 μm/sin 20°=1.46 μm, which is within 3 μm. This straight turningtool was fitted to a super-precision lathe (FIG. 3) with an offset angleof 20°, was set in a manner such that the step section of diffractivegrooves is parallel to the optical axis of the optical surface to beworked with an angular error of 1° or under, and the diffractive opticalsurface of the metal die for a plastic objective lens to be used for aDVD or a CD in either way was cut-worked. On the other hand, with astraight turning tool having rounded corner, which had been finished tohave a corner radius of the rake face 3 μm and a roundness of 50 nm orunder and was set at an offset angle of 20° to a super-precision lathe,the diffractive optical surface of a metal die for molding an objectivelens having the same shape as the above-mentioned for a pickup devicewas cut-worked. The conditions of cut-working are the same for both.After the measurement of the surface roughness Rz of the former andlatter metal dies obtained, the both metal dies were fitted in the samedie-fixture, and injection molding was performed in completely the sameconditions; thus, plastic objective lenses of the same specification forboth of a DVD or a CD were obtained respectively. These objective lenseswere actually loaded in a pickup unit, and the amplitude of aneye-pattern signal was measured for a DVD and a CD. The results of theabove-mentioned measurements were shown in Table 2. TABLE 2 SurfaceMaximum roughness width of of metal edge end/ DVD die Width of signal CDsignal Rz diffraction amplitude amplitude Lens molded 42.1 nm  3.8%1.756 Vpp 1.323 Vpp by metal die worked by straight tool Lens molded12.3 nm 21.1% 1.251 Vpp 1.278 Vpp by metal die worked by rounded tool

[0138] Although the surface roughness Rz of the worked metal die workedwith the straight turning tool is three times worse than that of themetal die worked with the rounded tool, light quantity loss owing toscattering is not produced nearly at all. On the contrary, because theratio of the width of the imperfect-shaped portion to the width of thediffractive grooves is nearly ⅙ of that for the rounded tool owing tothe corner radius R of the cutting edge being three times sharper,diffraction efficiency is remarkably improved; the amplitude value ofthe DVD signal which is more influenced by diffraction light is improvedby 29% more than the metal die worked with the straight turning toolhaving rounded corner. As the result of this, it was found that in ametal die cut-worked with a straight turning tool, so long as thesurface roughness Rz falls within a range from {fraction (1/1000)} to{fraction (1/10)} of the wavelength, and the ratio of the width of theimperfect-shaped portion to the width of the diffractive groovescut-worked falls within a range from 0.5% to 15%, scattering is little,and a sufficient quantity of transmitted light could be obtained.

EXAMPLE OF PRACTICE 2

[0139] With a straight tool having an apex angle of 30° whose corner ofthe cutting part lies within 1.3 μm from the virtual apex position, thediffractive optical surface of a metal die for molding an objective lensfor use in a pickup device using a light source wavelength of 405 nm wascut-worked. Before working, assuming the limit value of Rz was λ/10(40.5 nm), the radius R in the case where the corner of the cutting partwas regarded as an arc was calculated from the equation 2, to obtain 348nm. From this value and the limit value of Rz, feed rate was calculatedby using the equation (1), to obtain 244 nm/rev In accordance with thesecutting conditions, the number of revolutions of the spindle and thetool feed speed were set at 2000 rpm and 0.5 mm/min respectively, andcut-working was carried out. After fitting the finished metal die in adie-fixture, injection compression molding was carried out, to obtain aplastic objective lens which had a low birefringence and was excellentin the ability of transferring the shape of a metal die. The measuredquantity of transmitted light was 89.2% without reflection reducingcoating (the refractive index of the material n₄₀₀=1.55); it could beobtained almost an ideal value as compared with the calculated value9.3% (for both surfaces) for the loss of light quantity owing to surfacereflection for perpendicular incidence.

EXAMPLE OF PRACTICE 3

[0140] By using a three kinds of tools, which were a first straightturning tool having an apex angle of the cutting part of 40°, a firstclearance angle of 10°, and a second clearance angle of 40°, a secondstraight turning tool of a specification which was different from thefirst one in the apex angle being 30°, and was the same as the first onein other items, and a third straight turning tool having an apex angleof the cutting part of 30° and asymmetric inclination angles of theflanks of the cutting part, it was cut-worked, the diffractive opticalsurface of a metal die for molding a lens for use in a pickup device fora DVD, and the metal die had the maximum normal angle 53° at itsoutermost circumference, which was positioned outside the effectivediameter. A tool having an apex angle of the cutting part of 40° wasattached to a super-precision lathe with an offset angle of 20° to leftin such a manner that the step section of the diffractive grooves becameparallel to the optical axis of the optical surface to be worked with anangular error not greater than 1°, and cutting was started from theoutermost portion of the metal die; however, it was found that acone-shaped optical surface was generated in the outermost circumferenceportion, and the ridgeline of the rake face and the flank interfered themetal die. Therefore, the tool was switched over to the tool having theapex angle of the cutting part of 30°, with the tool holder left as itwas, and the tool was fitted with an offset angle of 20°, to cut-work;however, it was found that the ridge line of the flank and the secondclearance face was in contact with the metal die. Then, the clearanceangle of the second clearance face was measured, to find 38.5°, which isslightly under 40°, and it was found that the tool interference wasproduced for the reason that a tool having a small second clearanceangle owing to dispersion in manufacturing tools was used by chance.

[0141] Therefore, an asymmetric straight turning tool having an apexangle of 30° likewise, the inclination of flank of the cutting part tothe offset direction 0°, and the inclination of the other flank of thecutting part 4.9° is fitted to a super-precision lathe with an offsetangle of 20° to left, and the optical surface of a metal die wascut-worked again. No tool interference was produced, and because theclearance between the flank of the tool and the optical surface waslarge, the elimination of the cut scraps and the feeding-in of lubricantliquid could be sufficiently performed; as the result, a high-qualityoptical surface with less catching of chips was obtained. In thisconnection, the inclination angle of the flanks of the cutting part ofthe symmetric straight turning tool having the apex angle 30° whichproduced tool interference was 2° for both left and right sides.

[0142] From the above description, in the case of the tool having theapex angle of the cutting part 40°, the normal angle was90°−(40°/2+20°)=50°, which is smaller than the maximum normal angle 53°;therefore, it was backed up that tool interference was produced by theridgeline of the rake face and the flank. Further, in the case where theapex angle of the cutting part is 30° and the offset angle is 20°, thenormal angle was 90°−(30°/2+20°)=55°, it did not occur that the toolinterference was produced by the ridgeline of the rake face and theflank, but because the inclination angle of the flank of the cuttingpart was small, the tool interference was produced by the ridgeline ofthe flank and the second clearance face. However also in this case, bymaking the inclination angles of the flanks of the edge asymmetric, theclearance of the flank coming close to the optical surface of the metaldie could be made large, by which the production of tool interferencecould be suppressed.

EXAMPLE OF PRACTICE 4

[0143] By using an asymmetric straight turning tool having an apex angleof the cutting part of 25°, an angle of inclination of the secondclearance face of 40°, an angle of inclination of the right flank of4.9°, and an angle of inclination of the left flank of 0°, and anasymmetric straight turning tool having an apex angle of the cuttingpart of 25°, a first clearance angle of 10°, no second clearance face,the ridgeline of the second clearance angle formed by the intersectionof the left and right flanks, a second clearance angle of 40°, a firstinclination angle of 4.9° of the right flank, a second inclination angleof 20° of it, an inclination angle of 0° of the left flank, and nosecond inclination angle, the optical surface of a metal die for moldinga diffractive objective lens having the maximum normal angle 61.6° andthe NA 0.85 for use in a pickup device was cut-worked. It was understoodthat, for an offset angle of 15°, the normal angle for both tools became90°−(25°/2+15°)=62.5°, then the tool interference by the apex angle ofthe cutting part for the maximum normal angle could be avoided;therefore, the tool was set at the offset angle 15° to left to ansuper-precision lathe.

[0144] When the surface of a metal die was cut-worked with the formertool, the ridgeline of the right side face and the second clearance faceinterfered the metal die, and it occurred not only that the diffractiveoptical surface could not be generated, but also that the opticalsurface was damaged to a large extent, which made it unable to use it byreworking. Thus, a new piece of the same metal die was prepared andcut-worked with the latter tool; then it was found that toolinterference was not produced and the cut-working of the optical surfacecould be performed.

[0145] Regarding the flanks of the cutting part, only the one side mayhave two steps of inclination, or the inclination angle may be varied by1° or more for the left and right sides to make the shape asymmetric;further, also it is appropriate that the flanks have a shape which ishard to produce tool interference by increasing the clearance of thetool owing to a synergistic effect through making the combination ofthese. The scope of this invention covers each of means for avoidingtool interference and also the combination of them.

[0146] According to this invention, by making definite the values andthe ranges which are required for obtaining a sufficient quantity oftransmitted light, it is possible to provide a metal die capable ofactualizing the manufacturing of a diffractive optical element having ahigh efficiency, a tool for it, and an optical element manufactured byit.

What is claimed is:
 1. An optical element capable of transmitting light,comprising: an optical surface having an optical axis; diffractivegrooves provided on at least a part of the optical surface and each ofthe diffractive grooves including a first surface capable of beingapproximated by a predetermined optical function; a second surfaceextending in a direction to cross the first surface and being parallelto the optical axis with an angular error not greater than 10; and athird surface not approximated by the predetermined optical function andto connect the first surface and the second surface; wherein a width ofthe third surface in the direction perpendicular to the optical axis is0.5% to 15% of the sum of a width of the first surface in the directionperpendicular to the optical axis and the width of the third surface inthe direction perpendicular to the optical axis.
 2. The optical elementof claim 1, wherein the predetermined optical function is represented bythe following formula: N=INT(Ah ² +Bh ⁴ +C), X(h, N)=h ²/(r_(N)(1+°(1−(1+K _(N))h ² /r _(N) ²)))+A4_(N) h ⁴ +A6_(N) h ⁶ +A8_(N) h ⁸+A10_(N) h ¹⁰ +ΔN, where N denotes the number of a ring-shaped zone ofeach of the diffractive grooves, h denotes a height from the opticalaxis, X denotes a distance from a tangent plane in the direction of theoptical axis, r_(N) denotes a radius of a curvature of N-th ring-shapedzone, K_(N)A4_(N) to A10_(N) are coefficients of an aspherical surfaceof the N-th ring-shaped zone, and Δ=−λ₀/(n−1) denotes an amount of aface shift corresponding to 1λ₀ on the optical axis.
 3. The opticalelement of claim 1, wherein the optical element is a coupling lens foruse in an optical pickup apparatus used for an information recordingand/or reproducing apparatus.
 4. The optical element of claim 3, whereinthe optical element is an objective lens to converge a parallel lightflux parallel to the optical axis.
 5. The optical element of claim 3,wherein the optical element is an objective lens to converge a divergentlight flux divergent to the direction of the optical axis.
 6. Theoptical element of claim 3, wherein the optical element is a collimator.7. An optical element capable of transmitting light, comprising: anoptical surface having an optical axis; diffractive grooves provided onat least a part of the optical surface and each of the diffractivegrooves including a first surface capable of being approximated by apredetermined optical function; and a second surface extending in adirection to cross the first surface; wherein a surface roughness Rz ofthe first surface is not larger than {fraction (1/10)} of a usingwavelength of a light source.
 8. The optical element of claim 7, whereinthe predetermined optical function is represented by the followingformula: N=INT(Ah ² +Bh ⁴ +C), X(h, N)=h ²/(r _(N)(1+{squareroot}(1−(1+K _(N))h² /r _(N) ²)))+A4_(N) h ⁴ +A6_(N) h ⁶ +A8_(N) h ⁸+A10_(N) h ¹⁰ +ΔN, where N denotes the number of a ring-shaped zone ofeach of the diffractive grooves, h denotes a height from the opticalaxis, X denotes a distance from a tangent plane in the direction of theoptical axis, r_(N) denotes a radius of a curvature of N-th ring-shapedzone, K_(N)A4_(N) to A10_(N) are coefficients of an aspherical surfaceof the N-th ring-shaped zone, and Δ=−λ₀/(n−1) denotes an amount of aface shift corresponding to 1λ₀ on the optical axis.
 9. The opticalelement of claim 7, wherein a second surface is parallel to the opticalaxis with an angular error not greater than 1°.
 10. The optical elementof claim 7, wherein the optical element is a coupling lens for use in anoptical pickup apparatus used for an information recording and/orreproducing apparatus.
 11. The optical element of claim 7, wherein theoptical element is an objective lens to converge a parallel light fluxparallel to the direction of the optical axis.
 12. The optical elementof claim 7, wherein the optical element is an objective lens to convergea divergent light flux divergent to the direction of the optical axis.13. The optical element of claim 7, wherein the optical element is acollimator lens.
 14. A metallic die for molding an optical elementcapable of transmitting light, wherein the optical element comprises anoptical surface having an optical axis; diffractive grooves provided onat least a part of the optical surface and each of the diffractivegrooves including a first surface capable of being approximated by apredetermined optical function and a second surface extending in adirection to cross the first surface; the metallic die comprising: asurface corresponding to the first surface of the optical element,wherein the surface is formed by a rotating cutting process with acutting tool, and wherein a feed rate of the cutting tool in a radiusdirection is 0.1 μm to 1 μm per one rotation of the metallic die. 15.The metallic die of claim 14, wherein a second surface is parallel tothe optical axis with an angular error not greater than 1°.
 16. Anoptical element produced by injection molding or by injectioncompression molding with the metallic die recited in claim
 14. 17. Theoptical element of claim 16, wherein the predetermined optical functionis represented by the following formula: N=INT(Ah ² +Bh ⁴ +C), X(h, N)=h²/(r _(N)(1+{square root}(1−(1+K _(N))h ² /r _(N) ²)))+A4_(N) h ⁴+A6_(N) h ⁶ +A8_(N) h ⁸ +A10_(N) h ¹⁰ +ΔN, where N denotes the number ofa ring-shaped zone of each of the diffractive grooves, h denotes aheight from the optical axis, X denotes a distance from a tangent planein the direction of the optical axis, r_(N) denotes a radius of acurvature of N-th ring-shaped zone, K_(N)A4_(N) to A10_(N) arecoefficients of an aspherical surface of the N-th ring-shaped zone, andΔ=−λ₀/(n−1) denotes an amount of a face shift corresponding to 1λ₀ onthe optical axis.
 18. The optical element of claim 16, wherein theoptical element is a coupling lens for use in an optical pickupapparatus used for an information recording and/or reproducingapparatus.
 19. The optical element of claim 16, wherein the opticalelement is an objective lens to converge a parallel light flux parallelto the direction of the optical axis.
 20. The optical element of claim16, wherein the optical element is an objective lens to converge adivergent light flux divergent to the direction of the optical axis. 21.The optical element of claim 16, wherein the optical element is acollimator lens.
 22. A cutting tool for cutting a metallic die formolding an optical element capable of transmitting light, wherein theoptical element comprises an optical surface having an optical axis;diffractive grooves provided on at least a part of the optical surfaceand each of the diffractive grooves including a first surface capable ofbeing approximated by a predetermined optical function; a second surfaceextending in a direction to cross the first surface; and a third surfaceto connect the first surface and the second surface, and wherein the atleast a part of the metallic mold is formed by a rotating cuttingprocess with the cutting tool, the cutting tool comprising: a rake faceopposite to a rotation direction of the metallic die at the time of therotating cutting process; the rake face formed by a first edge to cut asurface of the metallic die corresponding to the second surface of theoptical element, a second edge extending in a direction to cross thefirst edge, and a third edge to connect the first edge and the secondedge and to cut a surface of the metallic mold corresponding to thethird surface of the optical element, wherein a first extending linefrom the first edge and a second extending line from the second edgecross at a crossing point and a distance between the crossing point andthe third edge is 0.1 μm to 3 μm.
 23. A metallic mold manufactured bythe cutting tool recited in claim
 22. 24. The metallic mold of claim 23,wherein a second surface is parallel to the optical axis with an angularerror not greater than 1°.
 25. An optical element produced by injectionmolding or by injection compression molding with the metallic dierecited in claim
 23. 26. The optical element of claim 25, wherein thepredetermined optical function is represented by the following formula:N=INT(Ah ² +Bh ⁴ +C), X(h, N)=h ²/(r _(N)(1+{square root}(1−(1+K _(N))h²/r _(N) ²)))+A4_(N) h ⁴ +A6_(N) h ⁶ +A8_(N) h ⁸ +A10_(N) h ¹⁰ +ΔN, whereN denotes the number of a ring-shaped zone of each of the diffractivegrooves, h denotes a height from the optical axis, X denotes a distancefrom a tangent plane in the direction of the optical axis, r_(N) denotesa radius of a curvature of N-th ring-shaped zone, K_(N)A4_(N) to A10_(N)are coefficients of an aspherical surface of the N-th ring-shaped zone,and Δ=−λ₀/(n−1) denotes an amount of a face shift corresponding to 1λ₀on the optical axis.
 27. The optical element of claim 25, wherein theoptical element is a coupling lens for use in an optical pickupapparatus used for an information recording and/or reproducingapparatus.
 28. The optical element of claim 25, wherein the opticalelement is an objective lens to converge a parallel light flux parallelto the direction of the optical axis.
 29. The optical element of claim24, wherein the optical element is an objective lens to converge adivergent light flux divergent to the direction of the optical axis. 30.The optical element of claim 24, wherein the optical element is acollimator lens.
 31. A cutting tool for cutting a metallic die formolding an optical element capable of transmitting light, wherein theoptical element comprises an optical surface having an optical axis;diffractive grooves provided on at least a part of the optical surfaceand each of the diffractive grooves including a first surface capable ofbeing approximated by a predetermined optical function; a second surfaceextending in a direction to cross the first surface; and a third surfaceto connect the first surface and the second surface, and wherein the atleast a part of the metallic mold is formed by a rotating cuttingprocess with the cutting tool, the cutting tool comprising: a rake faceopposite to a rotation direction of the metallic die at the time of therotating cutting process; the rake face formed by a first edge to cut asurface of the metallic die corresponding to the second surface of theoptical element, a second edge extending in a direction to cross thefirst edge, and a third edge to connect the first edge and the secondedge and to cut a surface of the metallic mold corresponding to thethird surface of the optical element, wherein an angle α formed betweenthe first edge and the second edge satisfies the following conditionalformula: θmax≦(90−(α/2+S)) where θmax is a maximum normal angle of themetallic die corresponding to the optical surface and S is a settingangle of the cutting tool to the optical axis of the optical surface.32. A metallic mold manufactured by the cutting tool recited in claim31.
 33. The metallic mold of claim 32, wherein a second surface isparallel to the optical axis with an angular error not greater than 1°.34. The metallic mold of claim 32, wherein the diffractive grooves areformed such that the maximum normal angle Θmax is 40° to 70°.
 35. Anoptical element produced by injection molding or by injectioncompression molding with the metallic die recited in claim
 32. 36. Theoptical element of claim 35, wherein the predetermined optical functionis represented by the following formula: N=INT(Ah ² +Bh ⁴ +C), X(h, N)=h²/(r _(N)(1+{square root}(1−(1+K _(N))h ² /r _(N) ²)))+A4_(N) h ⁴+A6_(N) h ⁶ +A8_(N) h ⁸ +A10_(N) h ¹⁰ +ΔN, where N denotes the number ofa ring-shaped zone of each of the diffractive grooves, h denotes aheight from the optical axis, X denotes a distance from a tangent planein the direction of the optical axis, r_(N) denotes a radius of acurvature of N-th ring-shaped zone, K_(N)A4_(N) to A10_(N) arecoefficients of an aspherical surface of the N-th ring-shaped zone, andΔ=−λ₀/(n−1) denotes an amount of a face shift corresponding to 1λ₀ onthe optical axis.
 37. The optical element of claim 35, wherein theoptical element is a coupling lens for use in an optical pickupapparatus used for an information recording and/or reproducingapparatus.
 38. The optical element of claim 35, wherein the opticalelement is an objective lens to converge a parallel light flux parallelto the direction of the optical axis.
 39. The optical element of claim35, wherein the optical element is an objective lens to converge adivergent light flux divergent to the direction of the optical axis. 40.The optical element of claim 35, wherein the optical element is acollimator lens.
 41. A cutting tool for cutting a metallic die formolding an optical element capable of transmitting light, wherein theoptical element comprises an optical surface having an optical axis;diffractive grooves provided on at least a part of the optical surfaceand each of the diffractive grooves including a first surface capable ofbeing approximated by a predetermined optical function; a second surfaceextending in a direction to cross the first surface; and a third surfaceto connect the first surface and the second surface, and wherein the atleast a part of the metallic mold is formed by a rotating cuttingprocess with the cutting tool, the cutting tool comprising: a rake faceopposite to a rotation direction of the metallic die at the time of therotating cutting process, the rake face formed by a first edge to cut asurface of the metallic die corresponding to the second surface of theoptical element, a second edge extending in a direction to cross thefirst edge, and a third edge to connect the first edge and the secondedge and to cut a surface of the metallic mold corresponding to thethird surface of the optical element, a first side surface forming thefirst edge with the rake face; and a second side surface forming thesecond edge with the rake face; wherein the first surface has a firstinclination angle to the rake face, the second surface has a secondinclination angle to the rake face, the first inclination angle isdifferent from the second inclination angle, and a difference betweenthe first inclination angle and the second inclination angle is 1° to20°.
 42. A metallic mold manufactured by the cutting tool recited inclaim
 41. 43. The metallic mold of claim 42, wherein a second surface isparallel to the optical axis with an angular error not greater than 1°.44. An optical element produced by injection molding or by injectioncompression molding with the metallic die recited in claim
 43. 45. Theoptical element of claim 44, wherein the predetermined optical functionis represented by the following formula: N=INT(Ah ² +Bh ⁴ +C), X(h, N)=h²/(r _(N)(1+{square root}(1−(1+K _(N))h² /r _(N) ²)))+A4_(N) h ⁴ +A6_(N)h ⁶ +A8_(N) h ⁸ +A10_(N) h ¹⁰ +ΔN, where N denotes the number of aring-shaped zone of each of the diffractive grooves, h denotes a heightfrom the optical axis, X denotes a distance from a tangent plane in thedirection of the optical axis, r_(N) denotes a radius of a curvature ofN-th ring-shaped zone, K_(N)A4_(N) to A10_(N) are coefficients of anaspherical surface of the N-th ring-shaped zone, and Δ=−λ₀/(n−1) denotesan amount of a face shift corresponding to 1λ₀ on the optical axis. 46.The optical element of claim 44, wherein the optical element is acoupling lens for use in an optical pickup apparatus used for aninformation recording and/or reproducing apparatus.
 47. The opticalelement of claim 44, wherein the optical element is an objective lens toconverge a parallel light flux parallel to the direction of the opticalaxis.
 48. The optical element of claim 44, wherein the optical elementis an objective lens to converge a divergent light flux divergent to thedirection of the optical axis.
 49. The optical element of claim 44,wherein the optical element is a collimator lens.
 50. A cutting tool forcutting a metallic die for molding an optical element capable oftransmitting light, wherein the optical element comprises an opticalsurface having an optical axis; diffractive grooves provided on at leasta part of the optical surface and each of the diffractive groovesincluding a first surface capable of being approximated by apredetermined optical function; a second surface extending in adirection to cross the first surface; and a third surface to connect thefirst surface and the second surface, and wherein the at least a part ofthe metallic mold is formed by a rotating cutting process with thecutting tool, the cutting tool comprising: a rake face opposite to arotation direction of the metallic die at the time of the rotatingcutting process; the rake face formed by a first edge to cut a surfaceof the metallic die corresponding to the second surface of the opticalelement, a second edge extending in a direction to cross the first edge,and a third edge to connect the first edge and the second edge and tocut a surface of the metallic mold corresponding to the third surface ofthe optical element, a first side surface forming the first edge withthe rake face; and a second side surface forming the second edge withthe rake face; wherein at least one of the first surface and the secondsurface has a first inclination angle to the rake face, crossing linesof the first surface and the second surface form a first clearanceangle, at least one of the first surface and the second surface has asecond inclination angle to the rake face, at least the side surfacehaving the second inclination angle and another side surface formcrossing lines and the crossing lines form a second clearance angle. 51.A metallic mold manufactured by the cutting tool recited in claim 50.52. The metallic mold of claim 51, wherein a second surface is parallelto the optical axis with an angular error not greater than 1°.
 53. Anoptical element produced by injection molding or by injectioncompression molding with the metallic die recited in claim
 52. 54. Theoptical element of claim 53, wherein the predetermined optical functionis represented by the following formula: N=INT(Ah ² +Bh ⁴ +C), X(h, N)=h²/(r _(N)(1+{square root}(1−(1+K _(N))h ² /r _(N) ²)))+A4_(N) h ⁴+A6_(N) h ⁶ +A8_(N) h ⁸ +A10_(N) h ¹⁰ +ΔN, where N denotes the number ofa ring-shaped zone of each of the diffractive grooves, h denotes aheight from the optical axis, X denotes a distance from a tangent planein the direction of the optical axis, r_(N) denotes a radius of acurvature of N-th ring-shaped zone, K_(N)A4_(N) to A10_(N) arecoefficients of an aspherical surface of the N-th ring-shaped zone, andΔ=−λ₀/(n−1) denotes an amount of a face shift corresponding to 1λ₀ onthe optical axis.
 55. The optical element of claim 53, wherein theoptical element is a coupling lens for use in an optical pickupapparatus used for an information recording and/or reproducingapparatus.
 56. The optical element of claim 53, wherein the opticalelement is a coupling lens to converge a parallel light flux parallel tothe direction of the optical axis.
 57. The optical element of claim 53,wherein the optical element is a coupling lens to converge a divergentlight flux parallel to the direction of the optical axis.
 58. Theoptical element of claim 53, wherein the optical element is acollimator.